Diamonite Electrathon America Racer

[Functional Artist]

What's the need for the saddle...some may ask?

Well...exactly what a saddle does
...spread out the load

So, I did some drawin's to help illustrate

If the front axle was just mounted with the strap brackets (only)

The entire weight, of the front of the racer would be "hanging on those (4) bolts
...that are just goin' thru ~3/16" fiberglass
&
Would probably look like this in a very short time
...& mainly just from the weight of the racer & gravity

Then, add in some maneuverin' (from side-ta-side)
...'cause this "is" the steerin' axle
...& they would probably look like this in a very short time

Add the weight "wear" to the maneuverability "wear"
...& ya start gettin' somethin' that looks about like this

By the time ya ger 'er back to the pits
...& you'll probably have...somethin' like this (technical term: wallered out)

Where as/by incorporatin' the saddle(s)
...them (4) bolts will now be "running" thru (4) bolt holes
...that are goin' thru (2) steel "plates"
...that will be "sandwiching" the ~3/16" FG
&
By designing the saddle(s) to curve under the front edge
...the (4) bolts that are mountin' the (2) strap brackets
...WILL NOT be "in shear" any longer
...& will NOW just be mainly "bolting" or "pinning" the strap brackets to the saddle(s)

* Hopefully that made sense

 

[Functional Artist]

Rear Saddle (CAD) work

I'ma thinkin' ta make 'er wrap around from the sides

...& wrap around from the bottom (remember its upside down) too

Transferred the "pattern' to some 18g. steel (sheet metal)

Drilled out the inner corners
...to help give us some nice rounded inner curves

* Step drill bit makes easy work of it

Just gotta connect the dots

Rear (outer) saddle
...all cut out

Test fit
* Notice this saddle will "cradle" the lower rear of the monocoque "tub"
...& then, connect/attach on (6) different "planes" or directions

 

[Functional Artist]

Some may ask...why the rear saddle is so big?

Well, it's a gonna be multi-component mount

As the rear trailing/swing arm will mount to it

...& it's the support/backin' plate for the "pad" suspension

Plus, the roll bar
...& probably the upper, shoulder, seat belt straps too

Trailing arm wheel mounting plates

Let's make 'em match

Just tackin' 'em in place

Next, I drilled the axle holes
...& again, these Step drill bits make "easy work of it"
...goin' from an 1/8" pilot hole to nice-n-smooth 5/8" holes in just a couple of minutes

&
you can use the next "step" to chamfer the holes a bit too

 

[ezcome-ezgo]

My $0.02: Make them the same size and, AND! glue them to the FG. This is about spreading load over as much of the surface as possible.

 

[Functional Artist]

My $0.02: Make them the same size and, AND! glue them to the FG. This is about spreading load over as much of the surface as possible.

Hey Ez,

Sounds good to me

 

[Functional Artist]

Got 'em welded on pretty goodly

Lookie, I accidentally did a couple of decent welds

Tried ta keep the out (exposed) side nice-n-clean
...&/so, looks about like this

 

[Denny]

Got 'em welded on pretty goodly
View attachment 162295
Lookie, I accidentally did a couple of decent welds
View attachment 162296
Tried ta keep the out (exposed) side nice-n-clean
...&/so, looks about like this
View attachment 162297

You need to talk to Terry about leaning how to weld improperly.

 

[Whitetrashrocker]

You missed your mark.

 

[Functional Artist]

You need to talk to Terry about leaning how to weld improperly.

Hey Denny,

I took T's $0.99 welding master class
...should I ask for my moneys back?

You missed your mark.


View attachment 162301

Hey WTR,

That mark was in a stupid place...anyways

 

[Functional Artist]

We need an axle bolt (5/8" x 7" w/fine thread & a matchin' Castle nut)
...so, me & my "fair weather friend" took a ride, to the specialty bolt store

Lookin' my steel "stuff", I found a piece of 11g that should work good for mountin' the motor

Rear swing/trailing arm "mock up"

Another view

 

[Denny]

While I do think you got your money’s worth, you should still ask for it back.

 

[Functional Artist]

While "mockin' up" the swing arm, I was thinkin' "what about ride height adjustment?"

First thought was that more (or less) of the suspension "pad" could be used to raise or lower the ride height
...but/then, thought that's kinda remedial
...& "we can make 'er more elegantly adjustable"

Suspension Pad mount adjustment-or solution

Goes together like this

Ta look like this

 

[Functional Artist]

The ride height adjustable apparatus
...just "slides" in ta place

These access holes make it easy
...ta be able ta weld the "threaded inserts" in ta place

Before weldin'
...I covered up most of the "patient"

T's online weldin' class
...also, showed me how ta do these "plug" type welds too (made it well worth the $0.99)

 

[Functional Artist]

Whilst that wasa dryin'
...I went ahead & added the last (2) re-enforcment layers of FG

1.) I layed the first layer across both the front & back panels (left ta right or horizontally)
...& had 'em wrap around ~6" on both sides
&
2.) I layed the second layer (from front to back)
...from the "nose" to the "tail"
...goin' across the top of the first layer

So, the "hood" area
...the floorboard
...& the rear "deck" area
...all have a layer of CSM
...(2) layers of criss-crossing 1708 Bi-axial FG cloth
...& then, (2) more layers of criss-crossing 1708 Bi-axial FG cloth

For a total of (5) layers of criss-crossing fiberglass cloth

The front & back "panels" of the "hump now have
...a layer of CSM
...(2) layers of criss-crossing 1708 Bi-axial FG cloth
...another (2) layers of criss-crossing 1708 Bi-axial FG cloth
...& then, (2) more layers of criss-crossing 1708 Bi-axial FG cloth

For a total of (7) layers of criss-crossing 1708 Bi-axial FG cloth

 

[Whitetrashrocker]

Whats the 7 layers come out to in thickness?